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Unread 03-25-2013, 08:10 PM   #1
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Location: Apex, NC
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Default OBC or CHARGER

Specs: 1997 48 volt Club Car DS serial series (no tow/run switch) Battery pack is @ 49.9 volts

Problem: Charger does not turn on.


I need to figure out if the problem is the OBC or the Charger.

I can open the charger and bypass the relay as per the picture below and the charger will charge the batteries...

Quote:
Originally Posted by Stevegrmich View Post
You can see if this helps. Note two wires in center of pic that are being jumped.

CAUTION: this bypasses the OBC and charger will not automatically shutoff . . . monitor the charger and only bypass long enough to bring pack voltage above 38v.



I have done the OBC reset as shown below, I do get the buzzer sound...

Resetting the Club Car On board computer - reset the OBC


To reset the OBC the following must be done in this
order:
If no Tow/Run Switch then skip that step

• Key Switch to Off
• Forward/Reverse to Neutral
• Tow/Run Switch to Tow
• Disconnect the Battery NEGATIVE (–) wire
from the Battery Minus terminal on the battery
pack.
• Put the Tow/Run to Run
• Forward/Reverse Switch to Reverse
• Key Switch to On
• Lock the throttle pedal down
The reverse buzzer will sound and go off in about 30
seconds. Leave the cart like that for 5 min to cause the
OBC to reset.
To reconnect the OBC back into the system:
• Key Switch to Off
• Forward/Reverse Switch to Neutral
• Tow/Run switch to Tow
• Reconnect the Batt – wire to the battery minus
terminal on the battery pack.


The charger will not come on....

Is this proper way to check the OBC?
Quote:
Originally Posted by shecky25 View Post
Check out Pic Below.



The (2) wires I stuck the DMM into (Polarity does not matter) are the wires coming into the charger from the cart. Since I was showing a voltage (42.8 ) means the cable is good and that the OBC is working because it is showing a voltage. (Correct me if I am wrong) Then we knew that the Relay was bad and I had to order another one.

The OBC on my cart is cream/yellow colored... If it is the OBC what part # do I need or is there a better idea ie: smart charger and omit the OBC?
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Unread 03-25-2013, 08:16 PM   #2
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Default Re: OBC or CHARGER

TahoeDawg...... Where are you?
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Unread 03-25-2013, 09:01 PM   #3
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Default Re: OBC or CHARGER

Quote:
Originally Posted by CRK View Post
Specs: 1997 48 volt Club Car DS serial series (no tow/run switch) Battery pack is @ 49.9 volts

Problem: Charger does not turn on.


I need to figure out if the problem is the OBC or the Charger.

I can open the charger and bypass the relay as per the picture below and the charger will charge the batteries...









The OBC on my cart is cream/yellow colored... If it is the OBC what part # do I need or is there a better idea ie: smart charger and omit the OBC?

. . . It seems that per the above, OBC is not functioning properly . . . can you try your charger on another cart? . . . that is easiest way to rule out a charger issue . . .


. . . the second part regarding eliminating the OBC is a personal decision . . . many people have done it . . .
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Unread 03-25-2013, 09:09 PM   #4
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Default Re: OBC or CHARGER

Thanks Steve! For posting up the pic of the charger and how to do the bypass on it..

I leaning towards the OBC too.

Are there any fuses to be checked?
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Unread 03-26-2013, 08:37 AM   #5
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Default Re: OBC or CHARGER

bump
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Unread 03-26-2013, 08:47 AM   #6
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Default Re: OBC or CHARGER

Quote:
Originally Posted by CRK View Post
Thanks Steve! For posting up the pic of the charger and how to do the bypass on it..

I leaning towards the OBC too.

Are there any fuses to be checked?
. . . look at fuse on back side of charger receptacle of cart . . there is a sense lead fuse that may be in a yellow casing . . .

or it may look like this pic:

Attachment 82227
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Unread 03-26-2013, 09:12 PM   #7
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Default Re: OBC or CHARGER

Ok I feel stupid!

In my haste to get these 3yr old batteries back to life from the dead I had a senior moment.

The charger was working fine and so was the OBC. After the last charge I wanted to give the batteries a kick in the pants! I plugged the charger back in right after it finished and it did not come on. I tried to unplug/replug it back in a few times in hopes it would charge the batteries some more.

I followed the directions to do the relay bypass which worked like a charm. I also kept a very close eye on the batteries while doing so. I wanted the pack to get to 63.5 volts before going to zero, which it did.

Then it happened.... I wired the relay back in, but mixed up what wire went where.. Hey I had a 50/50 chance of getting it right I was wrong


Tonight I decided I would switch the two and WA----LA! Its working


The good news is I dont need an OBC or a new charger.
The bad news is the best I can get the pack to is 50.20 volts just a click over 80%


Which brings up the next question, when do I really need to replace them?
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Unread 03-26-2013, 09:58 PM   #8
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Default Re: OBC or CHARGER

Quote:
Originally Posted by CRK View Post
Which brings up the next question, when do I really need to replace them?
Whenever they won't power the cart any longer and you have very little run time!
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Unread 03-26-2013, 10:44 PM   #9
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Default Re: OBC or CHARGER

I do what you tried to do all the time. The charger will do a full charge then about 12 to 24 hrs after the charger shut off automatically I unplug at the cart end and wait 30 seconds and plug it back in, and let it go until it shuts off again. This procedure has been working very well for the last 2 years. The batteries are 7 year old Trojan T875. They routinely charge to 90 to 95 percent of a full charge. This method is more than adequate for 18 holes of golf and a cruise around the neighborhood.


Tim
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Unread 03-26-2013, 11:01 PM   #10
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Default Re: OBC or CHARGER

I think you need to do a load test. I'm going to do one as well by clipping my leads from the DVOM on each battery & checking the voltage on acceleration. My fear is that by time I get to the last couple of batteries my voltage will be lower across the pack regardless. I got my pack up to a full charge but after sitting for less than a day my voltage reading showed about 75% charged. I don't know at what rate the batteries will discharge just by sitting in the cold north east but I still don't think it's right. Try the load test & see what happens before you decide to replace your batteries.
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